Poultry feeder with level sensor

ABSTRACT

A feed level sensor for a poultry feeding system is positioned within the drop tube of a control feeder of the feeding system. The sensor comprise a first light emitter/light detector pair to detect when the level of feed in the drop tube falls below a predetermined “empty” level and a second light emitter/light detector pair to detect when feed in the drop tube is at a predetermined “full” level in the drop tube. The sensor emits a “start” signal to activate a drive to deliver feed to the feeders along a feed line when it is detected that feed in the control feeder drop tube falls below the “empty” level and emits a “stop” signal to deactivate the drive when it detects that feed within the drop tube is at the “full” level.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims is a divisional of, and thus claims priority to,co-pending U.S. application Ser. No. 13/569,699 filed Aug. 8, 2012,which, in turn, claims priority to U.S. App. No. 61/521,639 filed Aug.9, 2011, both of which are incorporated herein by reference. Inaddition, this application is related to co-owned U.S. Pat. No.8,056,506 which claims priority to U.S. App. No. 61/150,454, filed onFeb. 6, 2009, both of which are incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND

A poultry feed system includes of a series of poultry feedersdistributed along a horizontal feed tube. Feed is moved through the feedtube typically by means of an auger. The individual feeders aresuspended from the feed line by means of a drop tube which is incommunication with the feed tube by means of an opening in the feedtube. As feed passes over the opening, the feed will drop through thetube to fill the feeder pan and associated drop tube with feed. As canbe appreciated, the feeders are generally filled sequentially, with thefeeders at the beginning of the feed line being filled first.

A control pan is placed at the end of the feed line. The level of feedin this control pan is monitored to activate and deactivate the supplyof feed to the feeders. Being at the end of the line, the control panwill be the last to receive any feed, so all feeders along the line arefilled before the control pan fills up. When the control pan is filled,the feed delivery system is deactivated. The feed system will again beactivated to fill the feeders when it is determined that the controlfeeder has been depleted of a determined amount of feed.

Typical means of detecting the level of feed in a control pan includemechanical switches, proximity switches, paddles, rotating devices,etc., each with their own limitations.

BRIEF SUMMARY

Briefly, a control feeder for use in a feed system (such as in a poultryhouse) is disclosed. The control feeder includes a feed pan adapted tohold a determined amount of feed and a drop tube which opens into thefeed pan. The drop tube is adapted and configured to be placed incommunication with a feed delivery tube of the feed system. The controlfeeder further includes a feed level sensor adapted to detect the levelof feed within the drop tube. The feed level sensor comprises at leastone light emitter and at least one light receiver, at least one of whichis positioned within the drop tube. The at least one light receiver ispositioned to receive light from the at least one light emitter, suchthat the feed level sensor emits a “start” signal when feed within thedrop tube is detected to be at or below be a predetermined “empty” leveland a “stop” signal when feed in the drop tube is detected to be at orabove a predetermined “full” level.

In accordance with one aspect of the sensor, the at least one lightemitter and light receiver are both positioned in the drop tube, and theat least one light emitter being positioned in the drop tube to directlight across a width of the drop tube.

In accordance with an aspect of the sensor, the at least one receiverand at least one emitter define a single row. In this instance, the“empty” level and “full” level are at the same height relative to thedrop tube.

In accordance with another aspect of the sensor, the at least onereceiver and the at least one emitter comprise two or more receivers andemitters, wherein the receivers and emitters defining at least two rowsof receiver/emitter pairs. In this instance, the “empty” level is belowthe “full” level, and the at least one sensor and at least one emittercomprise at least a first emitter/receiver pair positioned at the“empty” level in said drop tube and a second emitter/receiver pairpositioned at the “full” level in said drop tube.

In accordance with an aspect of the sensor, the feed level sensorcomprises a circuit board which is mounted within the drop tube, saidcircuit board including the at least one receiver and the at least oneemitter. The circuit board can be flexible.

In accordance with an aspect of the sensor, the at least one lightemitter is positioned and adapted to transmit light through a length ofthe drop tube. In this instance, the at least one light emitter can bepositioned at or above a top of the drop tube and the at least onereceiver can be positioned in the drop tube at a level below theemitter. The positions can be reversed, such that the at least one lightemitter is at a level below the light receiver.

In accordance with an aspect of the sensor, the control feeder caninclude a control box, and the light emitter can be positioned in thecontrol box. The control feeder can further include a light guide todirect light from the emitter into the drop tube, such that the lightfrom the emitter is transmitted along a length of the drop tube to bedetected by the receiver. In this instance, the at least one receivercomprises at least one receiver positioned at an “empty” level in thedrop tube and at least one receiver positioned at a “full” level in thedrop tube. The receivers at the full and empty levels all being arrangedto detect light transmitted by said emitters.

In another aspect, a feed level control for a control feeder of a feedsystem is provided. The feed level control comprises a light receiverand a light emitter; the light receiver being adapted to direct lightacross a width of the drop tube or along a length of the drop tube, andthe light receiver being positioned relative to the light emitter todetect light transmitted by the light emitter, whereby, when the lightreceiver receives light from the light emitter, the control emits a“start” signal and when said light receiver ceases to receive light fromsaid light emitter, the control emits a “stop” signal.

In an aspect of the control, the light receiver and light emitter arepositioned on a circuit board adapted to be received in a drop tube.

In an aspect of the control, the light receiver and light emitter eachcomprise a plurality of light receivers and emitters. The plurality oflight emitters and the plurality of light receivers can define two ormore rows of light emitters and light receivers, each said rowcomprising at least one light emitter and at least one light receiver.In this instance, one of the rows defines an “empty” level and anotherof the rows defines a “full” level, the “empty” and “full” levels beingaxially spaced from each other along a drop tube.

In one aspect of the control, the emitter is positioned to transmitlight along a length of said drop tube, and one of the emitter andreceiver is positioned above the other of the emitter and receiver. Inthis instance, the emitter can be positioned in a control housing; andthe feed control can include a light guide to direct light to transmitlight along a length of the drop tube. The light receiver is positionedin the drop tube, and in accordance with an aspect of the lightreceiver, can comprise a plurality of light receivers which define atleast two levels of light receivers: a lower level of light receiversdefining said “empty” level and an upper level of light receiversdefining a “full” level.

In a further aspect, a method for controlling a feed system (such as ina poultry house) is disclosed. The feed system comprises a feed line, afeed hopper located at one end of the feed line, a conveying devicewhich moves feed through the feed line, a drive for the conveying deviceand a control feeder in communication with the feed line to receive feedfrom the feed line through a drop tube. The control feeder comprises afeed level sensor in the drop tube. The method comprises activating thedrive when the sensor determines that feed in the drop tube falls belowan “empty” level in the drop tube; and deactivating the drive when thesensor determines that feed in the drop tube has reached a “full” levelin the drop tube. In accordance with the method, the “full” level isabove said “empty” level.

In accordance with an aspect of the method, the sensor comprises atleast one light emitter and at least one light receiver. The sensoremits a “start” signal to activate the drive when the light receiverreceives light from the light emitter; and the sensor emits a “stop” todeactivate the drive when the light receiver ceases to receive lightfrom the light emitter.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a schematic drawing of a feeding system for a poultry house;

FIG. 2 is a side elevational view of a feeder used in the feedingsystem;

FIG. 3 is a cross-sectional view of the feeder showing feed filling thedrop tube of the feeder;

FIG. 4 is a perspective view of a control pan feeder with a level sensorincorporated therein;

FIG. 5 is a perspective view of the grill of the control pan feeder withthe level sensor incorporated therein, the view of FIG. 5 being rotatedapproximately 180° relative to the view of FIG. 4;

FIG. 6 is a bottom perspective view of a drop tube of the control panfeeder with a feed level sensor positioned therein;

FIG. 7 is an enlarged top perspective view of the control pan feederlooking into a drop tube through a head box of the control pan feedershowing the placement of the level sensor in the drop tube;

FIG. 8 is a perspective view of the level sensor;

FIGS. 9A-C are schematic views of the level sensor; and

FIG. 10 is a schematic of the control system for the motor of the feedsystem.

Corresponding reference numerals will be used throughout the severalfigures of the drawings.

DETAILED DESCRIPTION

The following detailed description illustrates the invention by way ofexample and not by way of claimed limitation. This description willclearly enable one skilled in the art to make and use the claimedinvention, and describes several embodiments, adaptations, variations,alternatives and uses of the claimed invention, including what Ipresently believe is the best mode of carrying out the claimedinvention. Additionally, it is to be understood that the claimedinvention is not limited in its application to the details ofconstruction and the arrangements of components set forth in thefollowing description or illustrated in the drawings. The claimedinvention is capable of other embodiments and of being practiced orbeing carried out in various ways. Also, it is to be understood that thephraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting.

Referring now to the drawings and particularly to FIG. 1, a poultryhouse is indicated in its entirety at H. Typically, such poultry housesare long structures having a length of several hundred feet and a widthof about 40-60 feet. For example, a typical poultry house H may have alength of about 300 feet and house about 15,000-20,000 birds. Typically,these poultry houses are equipped with an automated feeding systemhaving one, two, or more feed lines FL which typically run lengthwise ofthe house. Each of these feed lines has a feed hopper FH which receivespoultry feed from a bulk feed tank BFT located outside of the poultryhouse. Each of the feed hoppers FH is connected to a feed conveyor FCcomprising a feed conveyor tube 14 through which an auger conveyorextends. The auger may be rotatably driven by an electric motor EMwithin its respective conveyor tube. Alternatively, the auger may be aso-called centerless or flexible auger, such as shown in the prior artU.S. Pat. No. 5,875,882, or other such conveying means. If such flexibleaugers are used, it will be understood that the feed conveyor FC may bean endless loop within the poultry house with each elongate side of theloop constituting one of the feed lines FL. It will be understood thatother types of feed conveying mechanisms, other than an auger can beused to deliver feed through the feed conveyor tube 14.

Each of the feed lines has a multiplicity of feeding stations FS spacedtherealong at substantially equal intervals (e.g., about 2.5 footintervals). For example, in a feed line having a length of about 280feet, there may be about 112 feed stations FS. Generally, growers preferto have about one feeding station FS for every 60-65 grown broilers.Each of the feeding stations FS is herein shown to include a feeder.

The feeding stations include a plurality of feeders 20 which are spacedalong the feed line FL and a control feeder or control pan 20Cpositioned at an end of the feed line FL. The feeders include a pan 22having a side wall 24 and a grill 26 which extends upwardly from theside wall. A drop tube 28 extends from the feed conveyor tube 14,through a ring in the grill 26 to deliver feed to the pan 22. Althoughthe feeders are shown to include a grill, the grill is not necessary. Infact, the feeder disclosed in U.S. Pat. No. D625,886 (which isincorporated herein by reference) does not include a grill. A skirt 29can be provided around the bottom of the drop tube, and the height ofthe skirt relative to the drop tube can be adjusted to adjust the levelto which feed fills the pan. As feed is delivered through the conveyortube 14, as noted above, the feed drops through the drop tube 28 of thespecific feeder 20, 20C under gravity. Once the feeder pan is filled toits predetermined level with feed, feed will continue to fill the droptube, so that the drop tube 28 will be filled with feed, as seen in FIG.3. As the birds in the poultry house consume the feed in the feed pan,the feed level in the pan will be maintained by the feed in the droptube, and the level of feed in the drop tube will lower. However, atsome point, there will be insufficient feed in the drop tube to maintainthe level of feed in the pan.

As noted above, a control pan 20C is placed at the end of the feed lineFL, and the level of feed in the control pan is monitored by a controlsystem to activate and deactivate the motor EM to control delivery offeed to the feeders through the feed conveying tube 14. Hence, the motorfor the auger (or other conveying mechanism) will not be activated untilthe control system determines that the feed in the control pan 20C hasfallen below a predetermined level.

With reference to FIGS. 4 and 5, the control pan 20C includes a head box30 having in inlet 14 i which, in a feed system, is connected to thefeed conveying tube 14. As seen in the illustrative embodiment, the headbox 30 is positioned above the grill 26 of the feeder 10. As notedabove, the feeder could be formed without the grill, in which case, thehead box would be at the upper end of the drop tube. As is known, theinlet tube 14 i is in communication with the drop tube 28 of the feeder20C, so that feed delivered into the head box will be delivered to thecontrol pan.

The motor EM is contained within (or adjacent) the head box 30 to drivethe feed conveying mechanism (i.e., an augur) (not shown) which movesthe feed through the conveyor tube 14. The head box 30 is constructed toisolate the motor EM from the feed delivered to the control pan throughthe head box 30. A control housing 32 (FIG. 4) houses a controller 34(FIG. 10) having a relay 36. The relay 36 is in electrical communicationwith the motor EM, and is controlled by the controller 34 to activateand deactivate the motor EM. A power cord 38 extends from the controlhousing 32 to a source of power. The power cord 38 places the controller34 and the motor EM in electrical communication with a source ofelectricity to provide electrical power to the controller and motor.

An illustrative embodiment of a feed level sensor 40 is shown in FIGS. 6and 7. As shown therein the feed level sensor 40 is mounted in the droptube slightly below the top of the drop tube (i.e., slightly below thebottom of the head box 30). The sensor 40 is in electrical communicationwith the controller 34 by means of a control cable 48. With reference toFIGS. 9A-C, the feed level sensor comprises a cylindrical transparentcircuit board which is sized to be received in the interior of the droptube 28, such that a back surface of the circuit board is adjacent theinner wall of the drop tube. The sensor 40 includes a plurality of lightemitters 44 and light receivers 46. The emitters 44 transmit infraredlight, and the receivers detect infrared light. However, if desired,emitters and receivers which operate with light in other wavelengthscould be used. The circuit board can also include microprocessor orcontroller 42 which would convey signals from the emitters and receivesto the controller 34. However, the microprocessor/controller 42 which isshown to be on the circuit board could be incorporated into thecontroller 34 which is remote from the sensor 40. The infrared emittersand receivers are electrically connected to the controller 42, forexample, by printed circuits in the flexible circuit board 40.

The circuit board 40 can be a flexible circuit board, which can then beprovided in a flat, or unrolled, condition, as shown in FIG. 9C. Theflat circuit board can then be rolled or curled into a cylinder to bereceived in the drop tube 28 of the feeder 20C. Alternatively, thesensor can be formed as a cylinder which is sized to be received in thedrop tube of the feeder.

The receivers 46 and the emitters 44 are shown to be formed in groups ofthree. The use of multiple receives and transmitters will reduce thepossibility of receiving a false signal from the sensor 40. Althoughshown as being formed in groups or sets of threes, the emitters andreceivers can be formed in groups or sets of two or four or more.Alternatively, the emitters and receivers can be formed in single pairs(i.e., one sensor and one receiver).

The receivers and the emitters are positioned on the circuit board, andthe circuit board is sized, such that when the board is positioned inthe drop tube 28, the receivers 46 will be able to detect the lightgenerated by the emitters. In FIG. 9B, the emitters are and receiversare show to be opposite each other (i.e., spaced apart by about 180°).However, such spacing is not necessary. Some emitters can produce afairly wide beam (i.e., a cone of light), which will be detected by areceiver. Thus a receiver need not be directly opposite the emitter todetect the light from the emitter. The receiver could, for example, bespaced 120° from the emitter.

The sensor includes two groups or two pair of receivers 46 and twogroups of emitters 44, the two groups being offset from each other. Thisprovides for two sets of emitters/receivers which emit infrared light atapproximately right angles to each other and axially off set from eachother. With one set of emitters/receives being axially offset from theother set of emitters/receivers, the two sets of emitters/receiversdefine an upper set of emitters/receivers and a lower set ofemitters/receivers when the board 40 is formed into a cylinder to bereceived in the drop tube 28. Although the emitter/receiver pairs areshown as defining an upper and lower set of emitter/receiver pairs, theemitters and receivers can all be placed at the same level, such thatthere is a single row of emitter/receivers.

As noted above, the light beam can be spread (i.e., as a cone). Thus,the receiver in the lower row (with reference to FIGS. 9A-C), coulddetect the light from the emitters in the upper row. Thus, although theemitters and receivers are formed in two rows, they would operate as asingle row of emitters and receivers. However, if the two rows ofemitters and receivers are spaced far enough apart, the receivers fromthe lower row would not detect the light from the emitters in the upperrow (and vice versa), and the sensor would thus have in fact two rows ofemitter/receiver pairs.

In the illustrative embodiment described so far, the emitter isdescribed is being positioned to be facing generally towards thereceiver. However, the light from the emitter can reach the receiver inother ways as well, for example, by a light guide or by reflection. Theuse of a light guide allows for controlling of the direction of thelight produced by the emitter, irrespective of the direction the emitteris facing. Hence, with light guides, the emitter and receiver can beseparated even further. For example, the emitter can be positioned inthe control housing 32 or the head box 30. Light guides can be used todirect the light transmitted from the emitter into the drop tube, suchthat the light traverses a length, instead of a width, of the drop tube.In this variation, the receivers will be positioned in the drop tube ata desired level in the drop tube. The receivers could be at or close tothe bottom of the drop tube, or they could be near the top of the droptube, or they could be anywhere along the length of the drop tube. Thelight guide would be configured such that the light from the emitterwould be directed towards the receivers, such that the receivers wouldsense or detect the light from the emitters. In this example, theemitters and receivers could each be placed on their own circuit board,and the two circuit boards could then be placed in communication withthe controller 34.

As is known, the receivers detect the light from the emitters, andproduce a first signal as long as the light is detected. When thereceiver no longer detects the light from the emitter, a second signalwill be produced by the receiver, indicative of the fact that it nolonger detects light.

In operation, as feed is eaten by the poultry in the poultry house, thelevel of feed in the feeder 20, and hence, the level of feed in the droptube 28, will drop. As long as the feed in the drop tube is above acertain “full” level, the receiver will not sense or detect light fromthe emitter. However, when the feed in the drop tube 28 falls below acertain “empty” level, the receivers will detect light from theemitters, and the sensor 40 will send a signal to the controller 34 viathe control cable 48, indicative of the fact that the feed has fallenbelow the predetermined “empty” level. This can be considered a “start”signal. At this point, the controller 34 will close the relay 36 toactivate the motor EM. Activation of the motor EM will begin driving theconveyor mechanism to deliver feed to the feeders 10 (including thecontrol pan) in the feed line. When the level of feed in the drop tube28 of the control pan 20C, again raises up to the “full” level, thereceiver will effectively be covered by grain and light from the emitterwill be blocked. The sensor 40 will thus send the second signal to thecontroller indicative of the fact that the grain has reached a “full”level within the drop tube. The controller will use this “stop” signalto open the relay to deactivate the motor EM, thereby stopping thedelivery of feed to the feeders.

In one variation of the control, when the emitters and receivers arearranged in levels or tiers, as shown in FIG. 9C, the “start” signal canbe sent when the feed falls below the level of the lower set of emittersand receivers, and the “stop” signal can be sent when the feed againreaches the level of the upper set of emitters and receivers. In thisinstance, the lower emitter/receiver pair defines the “empty” level inthe control feeder at which point the motor is activated to deliver feedto the feeders 20 and 20C along the feed line FL. Similarly, the upperemitter/receiver pair defines the “full” level which, when reached themotor is deactivated to stop delivery of feed through the feed system.In another alternative, when the sensors and receivers are formed intiers, as in FIG. 9C, the different tiers or rows of sensors can simplyprovide redundancy in the control of the feed system.

In another alternative, the emitters can be are arranged to projectlight axially along a length of the drop tube (rather than across awidth of the drop tube. In this alternative, receivers could be set attwo or more different heights in the drop tube, with the lower levelreceivers being at an “empty” level and upper level receivers being at a“full” level. Alternatively, the light emitters could be positionedbelow the receivers to transmit light upwardly through the drop tube. Inthis instance, there could be a plurality of light emitters which defineat least two rows of emitters; with a lower of the rows defining the“empty” level and the upper of the rows defining the “full” level. Inthis variation, when receivers begin to receive light from the emittersin the “empty” level row, the start signal will be sent to activate themotor EM; and when the receivers no longer receive light from theemitters in the “full” level row, a stop signal will be sent todeactivate the motor EM.

As noted above, the infrared receivers 46 and the infrared emitters 44are formed in groups of three. The use of groups of receivers andemitters reduces the potential for the sensor to emit a false signal.Thus, for the system sensor to issue a “start” signal, all threereceivers in the lower set of receives must be receiving or sensing thelight from the corresponding emitters. Similarly, for the system toissue a “stop” signal, all three receivers in the upper group ofreceivers must issue a signal that they are not receiving light fromtheir corresponding emitters. Although the emitters and receivers areshown as sets of three, the redundancy (which reduces the probability offalse signals) could be provided by using emitters and receives in setsof two, or sets of four or more.

As various changes could be made in the above constructions withoutdeparting from the scope of the claimed invention, it is intended thatall matter contained in the above description or shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense. For example, although the sensor 40 is shown to have twopair of emitters and receivers (defining an upper and lower set ofemitters and receivers), the sensor could be produced with a single pairof emitters and receivers or three or more pairs of emitters andreceivers. Although the emitters/receivers are disclosed to emit andreceive infrared light, light at other wavelengths could also be used bythe sensor. Although the sensor 40 is shown as being positioned in thedrop tube of the feeder, the sensor could be placed in locations in thefeed system that are proximate the drop tube. These examples are merelyillustrative.

1. A feed level controller for a control feeder of a feed system; thefeed level control comprising a light receiver and a light emitter; thelight receiver being adapted to direct light across a width of the droptube or along a length of the drop tube; the light receiver beingpositioned relative to the light emitter to detect light transmitted bythe light emitter whereby, when said light receiver receives light fromsaid light emitter, said controller emitting a “start” signal and whensaid light receiver ceases to receive light from said light emitter,said controller emitting a “stop” signal.
 2. The feed level controllerof claim 1 wherein said light receiver and light emitter are positionedon a circuit board and said circuit board is adapted to be positioned inthe drop tube.
 3. The feed level controller of claim 2 wherein saidlight receiver and said light emitter each comprise a plurality of lightreceivers and emitters.
 4. The feed level controller of claim 3 whereinsaid plurality of light emitters and said plurality of light receiversdefine only a single row of light emitters and light receivers.
 5. Thefeed level controller of claim 3 wherein said plurality of lightemitters and said plurality of light receivers define two or more rowsof light emitters and light receivers, each said row comprising at leastone light emitter and at least one light receiver.
 6. The feed levelcontroller of claim 5 wherein one of said rows defines an “empty” leveland another of said rows defines a “full” level, said “empty” and “full”levels being axially spaced from each other along said drop tube.
 7. Thefeed controller of claim 1 wherein said emitter is positioned totransmit light axially along a length of said drop tube; wherein one ofsaid emitter and receiver is positioned above the other of said emitterand receiver.
 8. The feed controller of claim 7 including a controlhousing; said emitter being positioned in said control housing; saidfeed controller including a light guide to direct light to transmitlight along a length of the drop tube.
 9. The feed controller of claim 8wherein said light receiver is positioned in said drop tube andcomprises a plurality of light receivers; said plurality of lightreceivers defining at least two levels of light receivers; a lower levelof said light receivers defining said “empty” level and an upper levelof said light receivers defining a “full” level.
 10. A method forcontrolling a feed system in a poultry house; the feed system comprisinga feed line, a feed hopper located at one end of the feed line, aconveying device which moves feed through the feed line, a drive for theconveying device and a control feeder in communication with the feedline to receive feed from the feed line through a drop tube; the controlfeeder comprising a feed level sensor in the drop tube; the methodcomprising: activating the drive when the sensor determines that feed inthe drop tube falls below an “empty” level in the drop tube; anddeactivating the drive when the sensor determines that feed in the droptube has reached a “full” level in the drop tube.
 11. The method ofclaim 10 wherein said “full” level is above said “empty” level.
 12. Themethod of claim 10 wherein said sensor comprises at least one lightemitter and at least one light receiver; said sensor emitting a “start”signal to activate said drive when said light receiver receives lightfrom said light emitter and said sensor emitting a “stop” to deactivatesaid drive when said light receiver ceases to receive light from saidlight emitter.